Microcrack mitigation during laser scanning of tungsten via preheating and alloying strategies

Vrancken, Bey; Ganeriwala, Rishi; Martin, Aiden A.; Matthews, Manyalibo J.

doi:10.1016/j.addma.2021.102158

Cited by 20 publications

(8 citation statements)

References 49 publications

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“…AM has multiple advantages [5,6], including increased design complexity, reduced manufacture time and material costs, etc. Therefore, the investigations of AM W become of particular interest [7][8][9][10][11][12].…”

Section: Introductionmentioning

confidence: 99%

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Dislocation evolution during additive manufacturing of tungsten

Cui¹,

Li²,

Wang³

et al. 2021

Modelling Simul. Mater. Sci. Eng.

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Additive manufacturing (AM) frequently encounters part quality issues such as geometrical inaccuracy, cracking, warping, etc. This is associated with its unique thermal and mechanical cycling during AM, as well as the material properties. Although many efforts have been spent on this problem, the underlying dislocation evolution mechanism during AM is still largely unknown, despite its essential role in the deformation and cracking behavior during AM and the properties of as-fabricated parts. In this work, a coupling method of three-dimensional dislocation dynamics and finite element method is established to disclose the mechanisms and features of dislocations during AM. Tungsten (W) is chosen as the investigated material due to its wide application. The internal thermal activated nature of dislocation mobility in W is taken into account. The correlations between the combined thermal and mechanical cycles and dislocation evolutions are disclosed. The effect of adding alloying element Ta in W is discussed from the perspectives of tuning dislocation mobility and introducing nanoparticles, which helps to understand why higher dislocation density and fewer microcracks are observed when adding Ta. The current work sheds new light on the long-standing debating of dislocation origin and evolutions in the AM field.

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Section: Introductionmentioning

confidence: 99%

“…An alternative approach to mitigate crack is adding alloying elements, such as ZrC, Ta, etc, which to some extent inhibits the crack formation [17,18]. However, the goal of completely eliminating microcracks is not achieved yet [8].…”

Section: Introductionmentioning

confidence: 99%

Dislocation evolution during additive manufacturing of tungsten

Cui¹,

Li²,

Wang³

et al. 2021

Modelling Simul. Mater. Sci. Eng.

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“…In addition to this, W is widely reported to be prone to microcracking during AM pro-cessing (e.g. [18]), which is not the case for Ta. This may be a factor in the observed material failure.…”

Section: Refractory Component-level Test Resultsmentioning

confidence: 99%

Endurance Testing of Engineering Model Additive-Manufactured High Temperature Resistojets Made from Inconel 625 and Tantalum

et al. 2022

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“…For refractory metals like tungsten, the high DBTT around 673 K is a consequence of the limited mobility in screw dislocations within the BCC lattice. 31 Heating the substrate above DBTT and/or temperature below which unwanted brittle phases are formed has been shown to improve printability. [31][32][33][34] Especially in the case of EBM, which inherently involves substrate pre-heating during the process, the processability of refractory materials can be enhanced.…”

Section: Substrate Heatingmentioning

confidence: 99%

“…31 Heating the substrate above DBTT and/or temperature below which unwanted brittle phases are formed has been shown to improve printability. [31][32][33][34] Especially in the case of EBM, which inherently involves substrate pre-heating during the process, the processability of refractory materials can be enhanced. 35,36 Figure 2(a) Shows a schematic representation of an experimental setup with substrate heating during the AM process.…”

Section: Substrate Heatingmentioning

confidence: 99%

Additive manufacturing of refractory metals and carbides for extreme environments: an overview

Mukherjee,

Gabourel,

Firdosy

et al. 2024

Science and Technology of Welding and Joining

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Refractory metals and their carbides possess extraordinary properties when subjected to high temperatures and extreme environments. Consequently, they can act as key material systems for advancing many sectors, including space, energy and defence. However, it has been difficult to process these materials using the conventional routes of manufacturing. Additive manufacturing (AM) has shown a lot of potential to overcome the challenges and develop new material systems with tailored properties. This review provides a fundamental understanding of the challenges in the processing of refractory metals and their carbides, including microcracking, formation of brittle oxide phases and high ductile to brittle transition temperature (DBTT). We also highlight some of the novel approaches that have been taken to improve the processability of these challenging material systems using AM. These include in-situ reactive printing, ultrasonic vibration, laser beam shaping, multi-laser deposition and substrate pre-heating with a focus on microstructural changes to improve the properties of printed parts.

show abstract

Microcrack mitigation during laser scanning of tungsten via preheating and alloying strategies

Cited by 20 publications

References 49 publications

Dislocation evolution during additive manufacturing of tungsten

Dislocation evolution during additive manufacturing of tungsten

Endurance Testing of Engineering Model Additive-Manufactured High Temperature Resistojets Made from Inconel 625 and Tantalum

Additive manufacturing of refractory metals and carbides for extreme environments: an overview

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